Exploratory development of foams from liquid crystal polymers

Two types of liquid crystal polymer (LCP) compositions were studied and evaluated as structural foam materials. One is a copolymer of 6-hydroxy-2-naphthoic acid, terephthalic acid, and p-acetoxyacetanilide (designed HNA/TA/AAA), and the other is a copolymer of p-hydroxybenzoic acid and 6-hydroxy-2-naphthoic acid (designated HBA/HNA). Experimental results showed that the extruded HNA/TA/AA foams have better mechanical quality and appearance than HBA/HNA foams. Heat treatment improved foam tensile strength and break elongation, but reduced their modulus. The injection molding results indicated that nitrogen foaming agents with a low-pressure process gave better void distribution in the injection molded LCP foams than those made by the conventional injection-molding machine and chemical blowing agents. However, in comparing LCP foams with other conventional plastic foams, HBA/HNA foams have better mechanical properties than foamed ABS and PS, but are comparable to PBT and inferior to polycarbonate foams, especially in heat-deflection temperature and impact resistance energy. These deficiencies are due to LCP molecules not having been fully oriented during the Union-Carbide low-pressure foaming process.